Video response system and method

Abstract

A system and method is disclosed for instructing personnel in the operation and servicing of machinery at a plant from a geographically remote service center employing trained personnel. The system and method includes monitoring operating machinery at the plant with a video camera and transmitting a video signal to a base unit associated with the plant having a high resolution monitor. Audio communication is also provided between plant personnel and the personnel at the service center wherein audio signals are received and transmitted through the base unit. The video and audio signals are processed together at the base unit for synchronous transmission over a telecommunication system to the remote service center. The machinery is monitored in the plant with a cordless portable video camera by moving the portable video camera to a desired area of the operating machinery which needs monitoring. Cordless headsets, worn by plant personnel attending the machinery, are utilized to provide audio communication through the base unit at the plant. The plant may be divided into a plurality of machinery zones having zone interface units hard wired to the base units. The video signal is transmitted using radio frequency (RF) transmissions to the zone interface unit, and then to the plant base unit. Switches may be used between the zone interface units and the base unit to provide reception of a strong video signal at the base units.

What is claimed is: 
     
       1. A method for servicing production and manufacturing machinery at a plant from a geographically remote service center employing trained service personnel comprising: viewing said machinery in said plant with a wireless portable video camera including a radio frequency transmitter for transmitting a video signal, and moving said portable video camera to a desired area of said machinery which needs servicing for generating said video signal containing an image of said machinery;   providing a base unit at said plant;   transmitting said video signal from said portable video camera to said base unit using, at least in part, said radio frequency transmitter;   transmitting an audio only signal to said base unit using a wireless, portable audio two-way component carried by plant personnel at said machinery in said plant to generate said audio only signal;   transmitting and receiving said audio only signals using a radio frequency transmission system and a transceiver having an associated transmitting antenna and a receiving antenna hard-wired to said transceiver wherein said transceiver is operatively associated with said base unit;   processing said video and audio only signals at said base unit for transmission over a telecommunication system;   processing said video and audio only signals by converting and compressing said video and audio only signals to provide compressed digital signals for transmission of high quality synchronized video and audio signals to said remote service center;   displaying said video signal on a monitor at said remote service center;   transmitting remote audio signals from said remote center to said base unit in said plant, and processing said remote audio signals for retransmission as audio only signals to said audio two-way component carried by said plant personnel at said machinery;   audibly communicating between plant personnel at said plant and said service personnel at said remote service center using said audio signals in real time two-way audio communications; and   providing technical assistance by said service personnel at said remote center to said plant personnel for said machinery while viewing said monitor and listening to said audio communications.   
     
     
       2. The method of claim 1 including mounting said portable video camera on a transportable carrier, and moving and focusing said camera on said operating machinery for servicing by using a remote controller. 
     
     
       3. The method of claim 1 including providing a fixed video camera at a viewing area of said machinery in said plant, and controlling the focusing of said video camera using a remote controller at said geographically remote service center so that said service personnel may focus upon an area of said operating machine for said servicing. 
     
     
       4. The method of claim 3 including using said fixed video camera affixed to a stationary mount in an area of said operating machinery which is controlled with respect to pan, tilt, and focus. 
     
     
       5. The method of claim 3 including using said fixed video camera affixed to said base unit which is controlled with respect to pan, tilt, and focus. 
     
     
       6. The method of claim 1 including providing a plurality of machinery zones within said plant, having respective zone units, and transmitting said video signal from said video camera to a selected zone unit, and from said zone unit to said base unit so that a video signal of high strength which provides high resolution is received from said zone unit. 
     
     
       7. The method of claim 6 including switching between said zone units depending upon the strength of said video signal to provide reception of said video signal of high strength at said base unit. 
     
     
       8. The method of claim 7 including using an automatic switch which automatically senses the strongest signal at one of zone units and transmits said video signal of maximum strength from said zone unit to said base unit. 
     
     
       9. The method of claim 6 including transmitting said video signal from said portable video camera to said zone units using radio frequency (RF) transmission. 
     
     
       10. The method of claim 9 including hard wiring said zone unit to said base unit. 
     
     
       11. The method of claim 1 including displaying said video signal using a high-resolution, studio-grade monitor. 
     
     
       12. The method of claim 11 including providing a base unit video camera at said base unit for providing a base unit video signal which may be transmitted over said telecommunication system to said remote service center, and providing a base unit video monitor for displaying said video signals simultaneously with said service center. 
     
     
       13. The method of claim 1 including providing a zoom unit at said plant having a zoom video camera for zooming in on details of machine parts and components for providing a zoom video signal of said details for transmission to said remote service center. 
     
     
       14. The method of claim 1 including separating said video signal into a plurality of bandwidths of digital signals and strapping said bandwidths together for transmission of said first video signal to said remote service center. 
     
     
       15. The method of claim 14 including strapping together three integrated services digital network lines of said telecommunication system, and using an inverse multiplexor device to obtain a bandwidth sufficient for transmitting said digital signals at a high data rate of at least 384 kilobits per second to provide a high resolution display. 
     
     
       16. A video response system for communicating the operation or servicing of production and manufacturing machinery between a plant where the machinery is located and a remote center comprising: a wireless, portable video camera for providing a video signal containing an image depicting at least a portion of said machinery in said plant and a radio frequency transmitter associated with said video camera for transmitting said video signal;   a video receiving antenna disposed in a receiving area of said machinery and portable video camera for receiving said video signal;   a two-way audio only communication system for the wireless transmission and reception of audio only signals by attending plant personnel at said machinery;   at least a first base unit located in said plant for receiving said video and audio only signals: said audio communication system including a two-way wireless, portable audio component carried by said plant personnel, and an audio transceiver associated with said base unit, said audio transceiver including a two-way antenna system having a receiving antenna for receiving audio only signals from said audio component carried by said plant personnel and a transmitting antenna for transmitting audio only signals from said base unit to said audio component carried by said plant personnel;   said audio transceiver being operatively associated with said base unit; and wherein said base unit comprises; a signal processor for receiving said video and audio only signals to convert said signals into compressed digital signals for high quality synchronized transmission of said video and audio signals to said remote center; and   an output interface for delivering said compressed video and audio digital signals in a form for delivery over a telecommunication system   a remote audio system at said remote center for receiving said audio signals and for transmitting remote audio signals to said base unit for retransmission as audio only signals to said audio component carried by said plant personnel;   so that real-time wireless video and two-way audio signals are provided for effective operation or servicing of the machinery--for retransmission from said base unit to said remote center.       
     
     
       17. The system of claim 16 wherein said audio communication system includes a receiving antenna and a transmitting antenna wired to said audio transceiver of said base unit for receiving and transmitting radio frequency (RF) audio signals. 
     
     
       18. The system of claim 17 wherein said audio system includes at least one wireless audio headset to be worn by said plant personnel for communicating with said transmitting and receiving antennas. 
     
     
       19. The system of claim 16 wherein said base unit includes a base unit camera for viewing personnel at the location of said base units and generating a base video signal, and a monitor for displaying said camera video signal or said base video signals. 
     
     
       20. The system of claim 16 wherein said base unit includes a microphone for receiving audio messages at the location of the base unit. 
     
     
       21. The system of claim 16 wherein said output interface includes an inverse multiplexor for strapping together a plurality of lines of an integrated services digital network to transmit said digital signals to a second base unit at said service center at a high data rate for generating a high resolution video display at said service center. 
     
     
       22. The system of claim 16 including a second base unit at said remote service center comprising: a video monitor for displaying said video signal from said first base unit;   an audio transceiver for receiving said audio signal from said first base unit, and producing an audible message at said service center; and   a signal processor for receiving said video signal from said first base unit, and processing said video signal for display on said monitor.   
     
     
       23. The system of claim 22 wherein said video monitor includes a high resolution monitor of studio-grade quality. 
     
     
       24. The system of claim 16 including at least one zone interface unit disposed within an area of said operating machinery for receiving said video signal from said wireless, portable video camera and transmitting said video signal to said first base unit. 
     
     
       25. The system of claim 24 including a radio frequency (RF) transmitter associated with said portable camera for transmitting said video signal to said zone interface unit. 
     
     
       26. The system of claim 24 including a plurality of said zone interface units associated with different zones of operating machinery, and including a switch for selecting a particular zone interface unit to provide a video signal of high quality with regard to the location of said portable video unit. 
     
     
       27. The system of claim 16 including a plurality of said zone interface units associated with different zones of operating machinery, and including a switch for selecting a particular zone interface unit to provide a video signal of high quality with regard to the location of said portable video unit. 
     
     
       28. The system of claim 27 wherein said first base unit is portable and may be moved to one of said zones as desired; and including a base unit cable for plugging said base unit into a zone interface unit, and said zone interface unit being wired to a telecommunication system for transmitting said video and audio signals to said service center. 
     
     
       29. The system of claim 28 including a line splitter device wired between said zone interface units and said telecommunication system, said spliter device having a switch to transmit signals from said zone interface unit into which said base unit is plugged. 
     
     
       30. The system of claim 16 including an integrated services digital network having a plurality of lines strapped together for transmitting said digital signals. 
     
     
       31. The system of claim 16 wherein said first base unit comprises a microphone for receiving audible messages from personnel at said plant for conversion into said audio signals by said audio transceiver. 
     
     
       32. The system of claim 16 including at least one wireless headset to be worn by a plant attendant for communicating with said audio system of said base unit. 
     
     
       33. The apparatus of the system of claim 16 wherein said first base unit comprises a video camera affixed to said base unit which is controllable in a pan, tilt, and focus operation. 
     
     
       34. The system of claim 16 wherein said wireless, portable video camera transmits a one-way video signal to said base unit via said video receiving antenna for retransmission to said remote center. 
     
     
       35. The system of claim 34 wherein said receiving antenna is hardwired to said base unit. 
     
     
       36. The system of claim 35 including a plurality of zone units disposed in different areas of said plant where machinery is located, each said zone unit having one of said video receiving antennas for receiving said one-way video signal when said portable video camera is in a selected zone wherein each said video antenna is hardwired to said base unit. 
     
     
       37. The system of claim 35 wherein said base unit includes a monitor for displaying said one-way video signal, and for displaying other video signals transmitted from said remote center to said base unit.